Electrode feedthru having pin attached to wire therein and method of manufacturing

ABSTRACT

Disclosed herein is an electrode feedthru assembly for an electronic device and method of manufacturing. The feedthru assembly includes a ferrule, an electrode assembly, and an elastomer. The ferrule includes a bore through which the electrode assembly is positioned. The electrode assembly includes an electrode wire attached to a crimp pin. The crimp pin includes a crimp terminal portion and a pin terminal portion, the crimp terminal portion crimped to the a portion of the electrode wire to form a connected portion of the electrode assembly. The elastomer is disposed in the bore of the ferrule between the ferrule and the electrode assembly. The elastomer is configured to electrically isolate the ferrule from the electrode assembly and to encapsulate at least the connected portion of the electrode assembly.

PRIORITY CLAIM

This application is a Continuation application of U.S. patentapplication Ser. No. 15/421,582 (Attorney Docket No. A17P3003US0), filed1 Feb. 2017, entitled “System for Repeated Delivery of ImplantableDevices”, and is incorporated herein by reference in its entirety toprovide continuity of disclosure.

BACKGROUND OF THE DISCLOSURE Field

The present disclosure relates to a feedthru assembly for an electronicdevice and, more particularly, to an electrode feedthru assembly for usein an electrolytic device such as a capacitor or a battery. The presentdisclosure also relates to methods of manufacturing such an electrodefeedthru assembly and a housing that incorporates the electrode feedthruassembly.

Background

Compact, high voltage capacitors and batteries are utilized as energystorage reservoirs in many applications, including implantable medicaldevices. They are required to have a high energy density, since it isdesirable to minimize the overall size of the implanted device. This isparticularly true of capacitors and batteries used in an ImplantableCardioverter Defibrillator (ICD), also referred to as an implantabledefibrillator, since these devices can occupy a significant amount ofspace in an ICD.

Electrolytic capacitors are used in ICDs because they have preferableproperties in terms of size, reliability, and ability to withstandrelatively high voltage. Conventionally, such electrolytic capacitorsinclude an etched aluminum foil anode, an aluminum foil or film cathode,and an interposed kraft paper or fabric gauze separator impregnated witha solvent-based liquid electrolyte. While aluminum is typically used forthe anode foils, other metals such as tantalum, magnesium, titanium,niobium, zirconium and zinc may be used.

A typical solvent-based liquid electrolyte may be a mixture of a weakacid and a salt of a weak acid, preferably a salt of the weak acidemployed, in a polyhydroxy alcohol solvent. The electrolytic orion-producing component of the electrolyte is the salt that is dissolvedin the solvent.

Electrolytic capacitors are typically formed into flat or cylindricalshapes. For a flat construction, the individual cathode and anode foilsor plates are stacked in an interleaved manner with separatorsinterposed there between, and the stack is encased in an aluminum case.For a cylindrical construction, the stacked plates are rolled up intothe form of a substantially cylindrical body, or wound roll, that isheld together with adhesive tape and is encased, with the aid ofsuitable insulation, in an aluminum tube or canister. In both flat andcylindrical constructions, connections to the anode and the cathode aremade via tabs that extend outward from the stack or roll. An aluminumwire may then be connected (e.g., via welding) to each tab.

A feedthru assembly, also referred to as a “feed thru,” “feedthrough,”or “feed through” (sometimes hyphenated) assembly, is commonly used topass an electrode through the case in which capacitor plates are held.Typically, a feedthru assembly is manufactured via a manual assemblymethod or an injection molding method. In a manual method, an aluminumwire is pulled through the center of a rubber gasket assembly. Next, thealuminum wire and rubber gasket assembly are pulled through a ferrulethat has been welded or manufactured into a capacitor case. The aluminumwire on the inside of the case is then welded to a tab on either theanode plates or cathode plates.

The feedthru assembly provides an electrode connection between the anodeplates, or the cathode plates, inside the capacitor case to anelectrical device on an outside of the capacitor case, while preventingthe electrolyte from leaking from the case. The manual assembly methodis robust and has a low leak rate, but a highly skilled operator isrequired to perform this operation, preventing automated manufacturingof the feedthru assembly. Further, the rubber feedthru material can havehigh variability in the material sealing properties and can be a sourceof contamination for the capacitor. Both issues can lead to a decreasein yield due to electrolyte leaking out of the case and capacitorfailure due to contamination.

In an injection molding method, an elastomer is formed between anelectrode, such as a wire or pin, and a ferrule to create an insertmolded feedthru assembly. This method is more production friendly, ascompared to the manual method. However, both methods produce a feedthruwith low tensile strength that is easily damaged, because the wire orpin conductor that goes through the feedthru is easily broken. Thisproblem is particularly acute in an aluminum electrolytic capacitorwhere the wire or pin must be formed of a high purity aluminum to becompatible with the chemistry of the capacitor. High purity aluminum hasa low tensile strength and therefore may be easily broken duringmanufacturing or later handling or use.

What is needed is a feedthru that is more easily manufactured and lesssusceptible to damage.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

The accompanying drawings, which are incorporated herein and form a partof the specification, illustrate embodiments of the present disclosureand, together with the description, further serve to explain theprinciples of the disclosure and to enable a person skilled in thepertinent art to make and use the embodiments.

FIG. 1A is a perspective view of an electrolytic capacitor, according toan embodiment of the present disclosure.

FIG. 1B is a schematic diagram illustrating a cross-section of theelectrolytic capacitor of FIG. 1A, according to an embodiment of thepresent disclosure.

FIG. 1C is a partial, cut-away view of portion B of the electrolyticcapacitor of FIG. 1A illustrating a feedthru assembly, according to anembodiment of the present disclosure.

FIG. 2 is a perspective view of a feedthru assembly, according to anembodiment of the present disclosure.

FIG. 3 is a cross-sectional view of the feedthru assembly of FIG. 2,according to an embodiment of the present disclosure.

FIG. 4 is a partial cross-sectional view of the electrolytic capacitorof FIG. 1C, according to an embodiment of the present disclosure.

FIG. 5A is an end view of a ferrule, according to an embodiment of thepresent disclosure.

FIG. 5B is a cross-sectional view of the ferrule of FIG. 5A taken acrosssection line E-E of FIG. 5A, according to an embodiment of the presentdisclosure.

FIG. 6A illustrates an electrode assembly, according to an embodiment ofthe present disclosure.

FIG. 6B is a cross-sectional view of the electrode assembly of FIG. 6Ataken across section line F-F of FIG. 6A, according to an embodiment ofthe present disclosure.

FIG. 6C is a perspective view of a crimp pin, according to an embodimentof the present disclosure.

FIG. 7 is a flowchart of a process for manufacturing the electrolyticcapacitor of FIGS. 1A-1C, according to an embodiment of the presentdisclosure.

FIG. 8 is a flowchart of a process for manufacturing the feedthruassembly of FIG. 2, according to an embodiment of the presentdisclosure.

The present disclosure will be described with reference to theaccompanying drawings. In the drawings, like reference numbers indicateidentical or functionally similar elements. Additionally, the left mostdigit(s) of a reference number identifies the drawing in which thereference number first appears.

DETAILED DESCRIPTION

The following detailed description of feedthru assemblies and methods ofmanufacturing refers to the accompanying drawings that illustrateexemplary embodiments consistent with these apparatuses and methods.Other embodiments are possible, and modifications may be made to theembodiments within the spirit and scope of the apparatuses and methodspresented herein. Therefore, the following detailed description is notmeant to limit the apparatuses and methods described herein. Rather, thescope of these methods and systems is defined by the appended claims.

It would be apparent to one of skill in the art that the feedthruassemblies and methods of manufacturing, as described below, may beimplemented in many different embodiments without departing from thescope of the description below. Thus, the operation and behavior of theapparatuses and methods will be described with the understanding thatmodifications and variations of the embodiments are possible, given thelevel of detail presented herein. For example, while the followingembodiments describe a feedthru assembly connected to an anode of acapacitor, the feedthru assembly of the present disclosure may beconnected to other elements such as a cathode and/or be in otherelectrical devices such as a battery. It will be apparent to a personskilled in the relevant art that the apparatuses and methods may also beemployed to produce feedthru assemblies for use in a variety of devicesand applications in addition to use in an implantable cardioverterdefibrillator (ICD).

FIGS. 1A-1C illustrate different views of an electrolytic capacitor 100,according to an embodiment of the present disclosure. As shown by FIG.1A, electrolytic capacitor 100 includes a housing 102 and a feedthruassembly 104. Housing 102 encloses and provides protection for elementswithin housing 102 and, in some embodiments, acts as an electricalconnection for an anode or a cathode contained within housing 102.Housing 102 may be formed of a material such as aluminum or stainlesssteel. However, it would be apparent to one skilled in the art that avariety of other metals or materials may be used to form housing 102.While FIGS. 1A-1C depict housing 102 and electrolytic capacitor 100formed in a D-shape, other shapes would be understood by one skilled inthe art.

As shown by FIG. 1B, housing 102 contains a capacitor stack 106, alsoreferred to as an anode/cathode stack, that includes a plurality ofcathode plates 110 a that alternate with a plurality of anode plates 112a, and are separated by a plurality of separators 114. Each of theplurality of cathode plates 110 a includes a tab 110 b, as shown by FIG.1C. Tabs 110 b for the plurality of cathode plates 110 a are connectedtogether, for example, through a welding process, to form a single,common cathode (the collection of electrically connected cathode plates110 a are referred to herein as cathode 110). Likewise, each of theplurality of anode plates 112 a includes a tab 112 b, and tabs 112 b forthe plurality of anode plates 112 a are connected together, for example,through a welding process, to form a single, common anode (thecollection of electrically connected anode plates 112 a are referred toherein as anode 112). Example materials used for the cathode 110 includealuminum, titanium, stainless steel, while example materials for theanode 112 include aluminum and tantalum.

A dielectric material 116 may be disposed on or around an outer surfaceof anode plate 112 a. Dielectric material 116 may be an oxide that isthermally grown on, or deposited onto, the surface of each anode plate112 a. A high-k (i.e., a high-dielectric constant) dielectric materialmay be used for dielectric material 116.

The plurality of separators 114 maintain a given separation between eachcathode plate 110 a and an adjacent anode plate 112 a within housing102. Additionally, the plurality of separators 114 prevent arcingbetween cathode plate 110 a and anode plate 112 a in spaces wheredielectric material 116 may be very thin or nonexistent, and/or where avoid within electrolyte 118 exists between cathode plate 110 a and anodeplate 112 a. The plurality of separators 114 may be formed of kraftpaper or fabric gauze impregnated with a solvent-based liquidelectrolyte.

A conductive electrolyte 118 fills the space between each of theelements within housing 102. Electrolyte 118 may be a polymer or liquidelectrolyte as would be understood by one skilled in the art. Exampleelectrolytes include ethylene glycol/boric acid based electrolytes andanhydrous electrolytes based on organic solvents such asdimethylformamide (DMF), dimethylacetamide (DMA), or gamma-butyrolactone(GBL).

It should be understood that the various elements and dimensions ofcapacitor 100 are not drawn to scale. Although cathode plates 110 a,anode plates 112 a, and separators 114, are illustrated as being spacedapart from one another for the convenience of illustration and labeling,it would be understood by one skilled in the art that such elements mayalso be stacked together in close physical contact with one another.

As shown by FIG. 1A, Housing 102 further comprises an aperture throughwhich feedthru assembly 104 is disposed. The aperture may be formed bystamping, laser cutting, drilling, beveling, or any other known method.Further, the aperture of housing 102 may be formed into shapes otherthan a circle, as would be apparent to one skilled in the art.

Feedthru assembly 104 is configured to provide an electrical connectionbetween anode 112 and an external component (not shown) of an ICD, suchas the electrical circuitry within an ICD or other implantable medicaldevice, while electrically isolating anode 112 and the electricalconnection thereto from housing 102 (which may be electrical connectedto cathode 110). Feedthru assembly 104 is further configured to preventleakage of electrolyte 118 from housing 102.

FIGS. 2-4 illustrate different views of feedthru assembly 104 bothassembled with and isolated from housing 102, and are used below indescribing feedthru assembly 104.

As shown, feedthru assembly 104 includes a ferrule 210, an electrodeassembly 220, and an elastomer structure 230. Ferrule 210 is a tubularstructure configured to be disposed within the aperture of housing 102,as shown by FIG. 4. FIGS. 5A-5B show additional views of ferrule 210.FIG. 5A illustrates an end view of ferrule 210, and FIG. 5B illustratesa cross-sectional view of the ferrule 210 taken along section line E-Eof FIG. 5A. An outside surface of ferrule 210 is configured to attach tohousing 102 within the aperture by, for example, a welding process toprevent leakage of electrolyte 118 between ferrule 210 and housing 102.Ferrule 210 is formed of a material configured to bond and seal tohousing 102 and as such may be formed of the same material as housing102 such as aluminum or stainless steel. However, it would be apparentto one skilled in the art that a variety of other metals or materialsmay be used.

In an embodiment, ferrule 210 has a stepped-shape formed from a reduceddiameter portion or notch 310, as shown by FIGS. 3 and 4. Notch 310facilitates placement of feedthru assembly 104 to a desired depth withinthe aperture of housing 102. As shown by FIGS. 5A-5B, ferrule 210 mayinclude a shoulder diameter size O which is greater than a notchdiameter size N of notch 310, as shown by FIG. 5B. Because of thereduced diameter size N of notch 310, the feedthru assembly 104 setswithin the aperture of housing 102 such that only a portion of ferrule210 is exposed to an exterior of housing 102.

Ferrule 210 also includes an inner shoulder 312, as shown by FIGS. 3 and4. Shoulder 312 aids in securing elastomer 230 in ferrule 210. As such,shoulder 312 includes a portion of ferrule 210 that protrudes intoelastomer 230. Shoulder 312 may be formed from a reduced diameterportion of ferrule 210 that extends around a circumference of an innersurface of ferrule 210. As shown by FIGS. 5A-5B, shoulder 312 has adiameter size S that is less than an inner diameter size I of ferrule210. While FIGS. 5A-5B illustrate shoulder 312 as a single continuousportion along the inner diameter of ferrule 210, it would be apparent toone skilled in the art that other forms of shoulder 312 may be formedwithin ferrule 210. For example, shoulder 312 may include one morecontinuous portions on ferrule 210 and/or discontinuous protrusions suchas bumps, ridges, or spikes along an inside surface of ferrule 210.

Electrode assembly 220 is configured to provide an electrical pathbetween an element on an interior of housing 102 (e.g., anode 112) andthe external component of the ICD. As shown by FIGS. 3 and 4, electrodeassembly 220 extends through ferrule 210. Electrode assembly 220includes a crimp pin 320 and an electrode wire 322. FIGS. 6A-6Cillustrate additional views of electrode assembly 220. FIG. 6Billustrates a cross-sectional view of electrode assembly 220 taken alongsection line F-F of FIG. 6A. FIG. 6C illustrates a perspective view ofcrimp pin 320, according to an embodiment of the present disclosure.

Crimp pin 320 is configured to connect to electrode wire 322 withinferrule 210. As shown by FIG. 6C, crimp pin 320 includes a crimpterminal portion 620 and a pin terminal portion 622. Crimp terminalportion 620 includes a contact area 624 configured to receive and crimpto a portion of electrode wire 322. As shown by FIGS. 3-4, crimpterminal portion 620 connects to a distal end of electrode wire 322. Pinterminal portion 622 is configured to provide a contact for electricalconnection with an external device, such as an ICD board.

Crimp pin 320 is formed of an electrically conductive material such asnickel, copper, brass, aluminum, or an alloy thereof. Further, amaterial that forms crimp pin 320 is mechanically formable to facilitatemanufacturing of electrode assembly 220. Electrode wire 322 is likewiseformed of an electrically conductive material such as aluminum, nickel,copper, brass, or an alloy thereof.

In an embodiment, electrode wire 322 is formed of a first material, andcrimp pin 320 is formed of a second material that is different from thefirst material. For example, electrode wire 322 may be formed of asubstantially pure grade of aluminum (e.g., for chemical compatibilitywith an electrolyte with an aluminum electrolytic capacitor), and crimppin 320 may be formed of 200 series nickel (e.g., to provide enhancedtensile strength, as compared to high grade aluminum, for mating withexternal connectors or conductors). In another example, electrode wire322 may be formed of an aluminum having a first grade, and crimp pin 320may be formed of an aluminum having a second grade. The second materialthat forms crimp pin 320 may also be formed of a material that has ahigh melting point, to prevent melting of crimp pin 320 duringmanufacturing of electrode assembly 220.

Use of the different materials to form electrode assembly 220 willprovide an electrode with greater strength than conventional electrodes.In particular, crimp pin 320 may be formed of a material that isstronger than conventional electrodes, while allowing electrode wire 322to be formed from a different material that is suitable for use inhousing 102. For example, crimp pin 310 may be formed of 200 seriesnickel having a diameter of 0.019 inches, and electrode wire 322 may beformed of a high purity aluminum having a diameter of 0.025 inches.Accordingly, use of different materials also allows a smaller diameterelectrode terminal that is significantly stronger than conventionalelectrode terminals.

In another embodiment, pin terminal portion 622 may be plated with athird conductive material that is different from the second conductivematerial that forms crimp pin 320. Examples of the third conductivematerials include gold, silver, platinum, or an alloy thereof. The thirdconductive material of pin terminal portion 622 is configured to improveelectrical conduction between electrode assembly 220 and an externaldevice and/or to prevent corrosion of crimp pin 320.

Crimp pin 320 crimps to electrode wire 322 at connection portion 324, asshown by FIGS. 3-4 and 6B. In an embodiment, crimp pin 320 connects toelectrode wire 322 by other methods in addition to or aside fromcrimping. For example, crimp pin 320 may be welded to electrode wire 322at connection portion 324 instead of, or in addition to, being crimped.In this example, welding crimp pin 320 to electrode wire 322, inaddition to being crimped together, further strengthens the connectionand electrical conduction between crimp pin 320 and electrode wire 322.In another example, crimp pin 320 may be welded to electrode wire 322 atconnection portion 324 without crimping the two portions of electrodeassembly 220 together.

Elastomer structure 230 is disposed between ferrule 210 and electrodeassembly 220. Elastomer structure 230 is formed of a material that isconfigured to electrically isolate ferrule 210 from electrode assembly220 and to prevent leakage of electrolyte 118 between ferrule 210 andelectrode assembly 220. As such, elastomer structure 230 encapsulates atleast a portion of electrode assembly 220. In particular, elastomerstructure 230 encapsulates at least connection portion 324 of electrodeassembly 220 to support and strengthen connection point 324. Elastomerstructure 230 is further formed of a material configured to withstandheat from a connecting process, such as welding, performed to connectferrule 210 to housing 102.

Examples of materials used to form elastomer structure 230 include aliquid elastomer such as a silicone or a thermal plastic materialincluding Polyether ether ketone (PEEK). However, it would be apparentto one skilled in the art that other materials may be used for formingelastomer structure 230. Elastomer structure 230 may be formed by aninjection molding process to encase electrode assembly 220 within theelastomer 230. However, depending on the specific elastomer used, othermethods of molding may be used for encasing electrode assembly 220. Forexample, conventional injection molding or transfer molding may be usedto perform the molding process of the present disclosure.

In an embodiment, elastomer structure 230 includes a recessed area 232(see FIGS. 2 and 3) configured to receive electrode wire 322 ifelectrode wire 322 is bent (e.g., at a 90 degree angle) for attachmentto a tab 112 b, as shown by FIGS. 1C and 4. Recessed area 232 may beformed during a molding process or after the molding process by way of aremoval or grinding process.

Methods of manufacturing electrical device 100 and feedthru assembly 104are described with respect to FIGS. 7-8. Although electrical device 100,feedthru assembly 104, and elements have been described, FIGS. 7-8describe additional details regarding more nuanced features with respectto FIGS. 1-4, 5A-5B, and 6A-6C.

FIG. 7 illustrates a flowchart of a process for manufacturingelectrolytic capacitor 100 of FIGS. 1A-1C, according to an embodiment ofthe present disclosure. Capacitor stack 106 is formed by layeringcathode plates 110 a, anode plates 112 a, and separators 114 (step 702).Capacitor stack 106 is formed such that cathode plates 110 a alternatewith anode plates 112 a and separators 114 are disposed between adjacentcathode plates 110 a and anode plates 112 a. Next, cathode tabs 110 bare connected together to form a single cathode 110, and anode tabs 112b are connected together to form a single anode 112 (step 704).Connection of cathode tabs 110 b and anode tabs 112 b may be performedby a welding process.

Electrode wire 322 of feedthru assembly 104 is then connected to anodetabs 112 b (step 706). During this step, a portion of electrode wire 322is laser welded to anode tabs 112 b. Further, electrode wire 322 may bebent and positioned close to anode tabs 112 b such that the bent portionis received within the recessed area 232 of elastomer structure 230.Next, capacitor stack 106 along with feedthru assembly 104 is insertedinto housing 102 such that feedthru assembly 104 protrudes through anaperture of the case portion of housing 102 (step 708). During thisstep, cathode tabs 110 b may be connected by, for example, a weldingprocess to housing 102. Feedthru assembly 104 is then connected to thecase portion of housing 102 (step 710). Connection of feedthru assembly104 and housing 102 may be performed by a laser welding process.

A lid portion of housing 102 is attached to the case portion of housing102 (step 712). The lid portion may be attached by way of a weldingprocess. Next, electrolyte 118 is introduced into housing 102 (step714). Electrolyte 118 may be introduced through a second aperture (notshown) in housing 102 by way of a vacuum process. The second aperture isthen sealed by a plug or an elastomer such as silicone (716). Oncesealed, the method of manufacturing electrolytic capacitor 100 ends(step 718).

FIG. 8 illustrates a flowchart of a process for manufacturing feedthruassembly 104 of FIG. 2, according to an embodiment of the presentdisclosure. Electrode assembly 220 is formed by connecting crimp pin 320to electrode wire 322 (step 802). Connection of crimp pin 320 andelectrode wire 322 may include crimping and/or welding crimp terminal620 to a portion of electrode wire 322 to form a connected portion 324of electrode assembly 220. Next, electrode assembly 220 is insertedwithin a bore of ferrule 210 (step 804). Electrode assembly 220 may bepositioned to be substantially concentric with an inside surface ferrule210. However, in an embodiment, electrode assembly 220 may be positionedoff-center, but spaced from an inside surface, of ferrule 210. Anelastomer 230 is then injected into a space between electrode assembly220 and ferrule 210 (step 806). In particular, elastomer 230encapsulates at least the connected portion of electrode assembly 220and leaves exposed at least a distal portion of pin terminal portion 622and a distal portion of electrode wire 322. Injection may be performedby a mold injection method. The elastomer 230 then cures to bond to boththe electrode assembly 220 and ferrule 210 (808). Once cured, the methodof manufacturing feedthru assembly 104 ends (810).

CONCLUSION

It is to be appreciated that the Detailed Description section, and notthe Summary and Abstract sections, is intended to be used to interpretthe claims. The Summary and Abstract sections may set forth one or more,but not all, exemplary embodiments of the present apparatuses andmethods as contemplated by the inventors, and thus, are not intended tolimit the present apparatuses and methods and the appended claims in anyway.

Moreover, while various embodiments of the present apparatuses andmethods have been described above, it should be understood that theyhave been presented by way of example, and not limitation. It will beapparent to persons skilled in the relevant art(s) that various changesin form and detail can be made therein without departing from the spiritand scope of the present apparatuses and methods. Thus, the presentapparatuses and methods should not be limited by any of the abovedescribed exemplary embodiments, but should be defined only inaccordance with the following claims and their equivalents.

In addition, it should be understood that the figures, which highlightthe functionality and advantages of the present apparatuses and methods,are presented for example purposes only. Moreover, the steps indicatedin the exemplary apparatuses and methods described above may in somecases be performed in a different order than the order described, andsome steps may be added, modified, or removed, without departing fromthe spirit and scope of the present system and method.

What is claimed is:
 1. A feedthru assembly for an electrolytic device, the feedthru comprising: a ferrule having a bore, the bore having a reduced diameter portion forming a shoulder; an electrode assembly positioned within the ferrule, the electrode assembly comprising: an electrode wire comprising a first portion and a second portion; and a pin comprising a first terminal and a second terminal, the first terminal attached to the first portion of the electrode wire to form a connected portion of the electrode assembly, the connected portion being positioned within the bore of the ferrule, the second portion of the electrode wire extending out from the ferrule in a direction away from the pin; and an elastomer disposed in the bore of the ferrule between the ferrule and the electrode assembly, the elastomer configured to electrically isolate the ferrule from the electrode assembly and to encapsulate at least the connected portion of the electrode assembly, the shoulder of the ferrule extending into the elastomer.
 2. The feedthru assembly of claim 1, wherein the electrode wire is formed of a first conductive material and the pin is formed of a second conductive material different from the first conductive material.
 3. The feedthru assembly of claim 1, wherein the first terminal attaches to the first portion by a crimp method or a welding method.
 4. The feedthru assembly of claim 2, wherein the first conductive material comprises aluminum and the second conductive material comprises nickel.
 5. The feedthru assembly of claim 4, wherein the pin terminal portion is plated with a third conductive material different from the second conductive material.
 6. The feedthru assembly of claim 5, wherein the third conductive material comprises gold.
 7. The feedthru assembly of claim 5, wherein the third conductive material is configured to prevent corrosion of the pin.
 8. The feedthru assembly of claim 1, wherein the second portion of the electrode wire-includes a bent portion, and the elastomer includes a recessed area in which the bent portion of the electrode wire is positioned.
 9. The feedthru assembly of claim 1, wherein the elastomer includes a portion extending out from the ferrule toward the electrode wire, the portion of the elastomer includes a recess, and a bent portion of the electrode wire is positioned in the recess.
 10. The feedthru assembly of claim 1, wherein the pin comprises 200 series nickel having a diameter of 0.019 inches, and the electrode wire comprises aluminum having a diameter of 0.025 inches.
 11. The feedthru assembly of claim 1, wherein the first terminal attaches to the first portion by a crimp method and a welding method.
 12. The feedthru assembly of claim 1, wherein the elastomer comprises a silicone or a thermal plastic material including Polyether ether ketone (PEEK). 